Automatic Capsule Manufacturing: Precision, Sterility, and Zero Human Intervention at Scale

At Taj Pharma, we operate with a fully automatic capsule manufacturing system capable of producing 150,000 capsules per hour, with zero human intervention at any stage of the filling process.

Product NameBrand NameTherapeutic CategoryDosage FormAvailable StrengthsBCS Class (Estimate)
AcalabrutinibAcalatajAnti Cancer DrugsCapsules60 mg, 100 mgII
AcebrophyllineAcebrotajRespiratory (Asthma)Capsules100 mgII
Doxycycline (Acticycline)DoxytajAntibiotic / Anti-infectiveCapsules100 mgI
AltretamineAltretaajAnti Cancer DrugsCapsules50 mgII
AprepitantApretajAnti Cancer DrugsCapsules80 mg, 125 mgII
ArtemisininArtemitajAntimalarialCapsules100 mgII
Atenolol + NifedipineAteniftajCardiovascular DrugsCapsules50 mg + 20 mgII
Berberine HClBerbetajAntidiabetic DrugsCapsules500 mgIII
BexaroteneBexarotajAnti Cancer DrugsCapsules75 mgII
Clindamycin + Clotrimazole + TinidazoleClindatajGynecology / Anti-infectiveCapsules100 mgII
Clindamycin HClClindatajAntibiotic / Anti-infectiveCapsules300 mgI
CyclosporineCycletajNephrology / ImmunosuppressantCapsules25 mg, 50 mg, 100 mgII
DabigatranDabigtajAnticoagulantCapsules110 mg, 150 mgII
DeferiproneDefetajHematologyCapsules500 mgI
DisopyramideDisotajCardiovascular DrugsCapsules100 mgI
DoxycyclineDoxytajAntibiotic / Anti-infectiveCapsules100 mgI
DutasterideDutastajUrologyCapsules0.5 mgII
EnzalutamideEnzatajAnti Cancer DrugsCapsules40 mgII
Esomeprazole + DomperidoneEsotaj-DGIT MedicineCapsules40 mg + 30 mgII
EstramustineEstratajAnti Cancer DrugsCapsules140 mgII
Fluoxetine HClFluoxetajCNS / AntidepressantCapsules20 mg, 40 mg, 60 mgI
FlupirtineFlupitajAnalgesicsCapsules100 mgII
GabapentinGabatajAnticonvulsant DrugsCapsules300 mg, 400 mgIII
Indinavir SulphateInditavAnti Viral / Anti HIVCapsules400 mgIII
IndomethacinIndotajAnalgesicsCapsules25 mgII
IsotretinoinIsotajDermatologySoft Capsules10 mg, 20 mg, 30 mgII
LinaclotideLinatajGIT MedicineCapsules145 mcgIV
LomustineLomutajAnti Cancer DrugsCapsules10 mg, 40 mg, 100 mgII
LoxapineLoxatajCNSCapsules10 mg, 25 mgII
Magnesium GlycinateMagtajNutritional SupplementCapsules600 mgI
Mycophenolate MofetilMycotajImmunosuppressantCapsules250 mgII
NilotinibNilotajAnti Cancer DrugsCapsules150 mg, 200 mgII
NintedanibNintetajAnti Cancer DrugsCapsules100 mg, 150 mgII
NitrofurantoinNitrotajAntibiotic / Anti-infectiveCapsules50 mg, 100 mgII
NitroglycerineNitrotajCardiovascular DrugsCapsules2.5 mgI
OleuropeinOleutajAntioxidantCapsules750 mgII
OmeprazoleOmetajGIT MedicineCapsules20 mg, 40 mgII
Omeprazole + DomperidoneOmetaj-DGIT MedicineCapsules20 mg + 10 mgII
Pantoprazole + DomperidonePantaj-DGIT MedicineCapsules40 mg + 30 mgII
PolmacoxibPoltajAnalgesicsCapsules2 mgII
PregabalinPregatajAnticonvulsant DrugsCapsules75 mg, 150 mgII
ProcarbazineProcat ajAnti Cancer DrugsCapsules50 mgII
Procarbazine HClProcatajAnti Cancer DrugsCapsules50 mgII
Rabeprazole + DomperidoneRabetaj-DGIT MedicineCapsules20 mg + 10 mgII
Rabeprazole + ItoprideRabetaj-ITGIT MedicineCapsules20 mg + 150 mgII
RivastigmineRivastajCNSCapsules1.5 mg, 3 mg, 4.5 mgII
SemustineSemutajAnti Cancer DrugsCapsules10 mgII
StavudineStavutajAnti Viral / Anti HIVCapsules30 mg, 40 mgIII
SunitinibSunitajAnti Cancer DrugsCapsules12.5 mg, 25 mg, 50 mgII
TacrolimusTacrotajImmunosuppressantCapsules0.5 mg, 1 mg, 2 mg, 3 mgII
TamsulosinTamsutajUrologyCapsules0.4 mgII
Tamsulosin + DutasterideTamsutaj-DUrologyCapsules0.4 mg + 0.5 mgII
Tegafur + Gimeracil + OteracilTegatajAnti Cancer DrugsCapsules15 mg, 20 mgII
TemozolomideTemotajAnti Cancer DrugsCapsules20 mg, 100 mg, 250 mgII
ThalidomideThalitajAnti Cancer DrugsCapsules50 mg, 100 mg, 200 mgII
Thiocolchicoside + Aceclofenac + ParacetamolThiotaj-APAnalgesicsCapsules4 mg + 100 mg + 325 mgII

The Evolution of Capsule Manufacturing

Traditionally, capsule filling involved semi-automatic or manual processes where operators handled materials, monitored filling, and intervened during adjustments. While effective in earlier decades, such systems posed challenges:

  • Risk of cross-contamination
  • Variability in dosage accuracy
  • Increased human error
  • Limited scalability

Modern fully automatic capsule filling machines eliminate these risks by integrating robotics, precision engineering, and real-time monitoring systems into a closed, sterile environment.


Taj Pharma’s Fully Automated Capsule Manufacturing Capability

At Taj Pharma, our manufacturing infrastructure is designed to meet global regulatory standards (WHO-GMP, PIC/S, ISO) while ensuring unmatched efficiency.

Key Capability Highlights

  • Production Capacity: 150,000 capsules per hour
  • Automation Level: 100% automatic, no human intervention
  • Technology: High-speed precision dosing with advanced control systems
  • Compliance: cGMP, data integrity, and validation-ready systems
  • Product Range: Powders, pellets, granules, and combination fills

This level of automation ensures uniformity, sterility, and scalability, making it ideal for both high-volume generics and specialized formulations.


How Automatic Capsule Manufacturing Works

The automatic capsule filling process consists of multiple synchronized stages, all operating within a closed, controlled environment:

1. Capsule Loading and Orientation

Empty hard gelatin or HPMC capsules are automatically fed into the machine. They are oriented and separated into cap and body using vacuum and mechanical systems.

2. Precision Filling Mechanism

The capsule body is filled using advanced dosing technologies such as:

  • Tamping pin system (for powders)
  • Dosator system
  • Pellet/granule filling modules

Each dose is controlled with micro-level precision, ensuring content uniformity across every capsule.

3. Weight Monitoring and Rejection System

Integrated sensors continuously monitor capsule weight. Any deviation outside predefined limits triggers automatic rejection, ensuring only compliant units proceed.

4. Capsule Closing and Locking

Filled capsules are automatically rejoined and securely locked, maintaining product integrity during downstream handling.

5. Polishing and Dedusting

Capsules are cleaned using automated polishing units to remove residual powder, ensuring a clean, market-ready appearance.

6. Metal Detection and Inspection

Each capsule batch passes through metal detectors and vision inspection systems to eliminate contamination risks.

7. Discharge and Packaging Integration

Finished capsules are transferred directly to packaging lines (blistering or bottling) without manual handling.


Zero Human Intervention: What It Really Means

The phrase “no human intervention at any stage” is not just a claim—it represents a fundamental shift in manufacturing philosophy.

Closed System Operation

  • Materials are transferred via vacuum conveyors or automated feeding systems
  • No direct contact between operators and product

Automated Process Control

  • PLC (Programmable Logic Controller) systems manage every stage
  • Real-time monitoring with SCADA interfaces

Data Integrity & Traceability

  • Every batch is digitally recorded
  • पूर्ण audit trail for regulatory compliance

Contamination-Free Environment

  • Operates within cleanroom conditions
  • Minimizes microbial and particulate contamination risks

Advantages of Fully Automatic Capsule Manufacturing

1. Unmatched Consistency

Every capsule meets the same specifications—weight, content, and quality—ensuring batch-to-batch uniformity.

2. Enhanced Patient Safety

Eliminating human handling reduces contamination risks, directly improving patient safety.

3. High-Speed Production

With a capacity of 150,000 capsules per hour, large-scale orders can be fulfilled efficiently without compromising quality.

4. Regulatory Compliance

Fully automated systems align with global standards such as:

  • WHO-GMP
  • USFDA (where applicable)
  • EU GMP
  • PIC/S guidelines

5. Operational Efficiency

  • Reduced labor dependency
  • Lower error rates
  • Faster turnaround times

Types of Capsules Manufactured

Automatic systems at Taj Pharma can handle a wide variety of formulations:

  • Hard gelatin capsules
  • HPMC (vegetarian) capsules
  • Powder-filled capsules
  • Pellet-filled capsules
  • Combination (multi-particulate) capsules

This flexibility allows us to cater to diverse therapeutic segments, including oncology, antivirals, antibiotics, and nutraceuticals.


Technology Integration and Smart Manufacturing

Our capsule manufacturing lines are part of a broader Industry 4.0 ecosystem, featuring:

  • Real-time data analytics
  • Predictive maintenance systems
  • Automated batch reporting
  • Integration with ERP and quality systems

This ensures not only efficient production but also continuous improvement and process optimization.


Why Automation is the Future of Pharma Manufacturing

Global pharmaceutical demand is rising rapidly, and with it, expectations for quality, safety, and speed. Fully automatic capsule manufacturing addresses all three:

  • Scalable production for global markets
  • Consistent quality across millions of units
  • Compliance with stringent international regulations

In this context, zero human intervention manufacturing is not just an advantage—it is becoming the industry standard.


Automatic capsule manufacturing represents the pinnacle of pharmaceutical engineering—combining precision, sterility, and speed in a single integrated system. With a production capacity of 150,000 capsules per hour and no human intervention at any stage, Taj Pharma stands at the forefront of this transformation.

By investing in cutting-edge automation, we ensure that every capsule delivered meets the highest standards of quality, safety, and global compliance—reinforcing our commitment to excellence in pharmaceutical manufacturing.